Insulated curtain wall structure



Nov. 6, 1962 J. H, zlTTLE INSULATEU CURTAIN WALL STRUCTURE 2 Sheets-Sheet l Filed OCT.. 30, 1958 Nov. 6, 1962 J. H. zlTTLE 3,062,337

INSULATED CURTAIN WALL STRUCTURE Filed Oct. 30, 1958 2 Sheets-Sheet 2 Y" Ln N fg. -E'H P4 Il Q q, INVENTOR BY ENLA/ ATTORNEY V43,062,337 Patented Nov. 6, 1962 3,062,337 INSULATED CURTAIN WALL STRUCTURE John H. Zittle, Mountville, Pa., assignor to Howe Sound Company, Lancaster, Pa., a corporation of Delaware Filed Oct. 30, 1958, Ser. No. 770,739 '7 Claims. (Cl. 189-34) My invention relates broadly to building construction and more particularly to a curtain wall panel assembly having high thermal insulation properties.

One of the objects of my invention is to provide a construction of sandwich wall or curtain wall structure embodying metallic partition sheeting fabricated in sections with sound deadening and heat insulation material between the metallic sheets in combinationwith means preventing heat conduction between the partition sheets.

Another object of my invention is to provide a partition wall structure formed from metallic sheetin-g spaced from each other by poly-urethane foam using the urethane as the bonding agent for bonding the inner and outer surfaces of the metallic sheeting, in combination with interior ribs extending from one metallic sheet at one side of the partition toward the other metallic sheet at the other side of the partition with neoprene or vinyl spacers so interposed between the ribs and the coacting metallic sheet that direct heat conduction therethrough is prevented.

A still further object of my invention is to provide a construction of metallic partition material having both sound deadening and heat insulation properties in which special forms of heat insulation couplings are provided between coacting ends of adjacent sections of the wall structure for reducing heat conduction through the wall.

Other and further objects of my invention reside in a practical mass-produced metallic wall structure employing neoprene or vinyl spacers and couplings between parts of the wall structure for reducing heat transfer through the wall sections to eliminate transmission of heat or cold otherwise resulting from metal to metal contact as set forth more fully in the specification hereinafter following by reference to the accompanying drawings in which:

FIGURE 1 is a transverse horizontal view through a wall structure embodying my invention;

FIG. 2 is an enlarged and foreshortened transverse section of the wall structure shown in FIG. 1 and showing particularly the insulation means employed in the wall structure, the insulation means being illustrated in section;

FIG. 3 is a fragmentary sectional View taken on line 3 3 of FIG. 2;

l FIG. 4 is a fragmentary sectional view taken on line 4 4 of FIG. 2;

FIG. 5 is a fragmentary cross sectional view taken on line 5 5 of FIG. 2;

FIG. 6 is a fragmentary longitudinal sectional view taken on line 6-6 of FIG. 2;

FIG. 7 is a transverse sectional view on line 7 7 of FIG. 2;

. FIG. 8 is a fragmentary perspective view of the wall structure of my invention partially in cut-away section and particularly showing the application and positioning of the different insulator spacer members;

FIG. 9 is a foreshortened elevational view of one of the coupling insulators used in the structure of my invention;

FIG. l0 is a transverse sectional View on line 10 10 of FIG. 9;

FIG. 1l is a foreshortened sectional view on line 11-11 of FIG. l0;

FIG. l2 is an enlarged cross sectional view through one of the rib insulators used in the structure of my invention taken on line 12 12 of FIG. 14;

FIG. 13 is a cross sectional view on line 13 13 of FIG. 12;

FIG. 14 is an elevational View of one of the rib insulators used in the structure of my invention looking at one side thereof;

FIG. 15 is a foreshortened side elevational view of one of the end insulator members used in the structure of my invention;

FIG. 16 is a foreshortened transverse sectional view taken on line 16-16 of FIG. 15 g and FIG. 17 is a vertical sectional View taken on line 17-17 of FIG. 15.

My invention is directed to a construction of a sandwich wall or curtain wall structure consisting of spaced metallic sheet material with the space therebetween filled with poly-urethane foam, using the urethane as the bonding agent for bonding the opposite metallic surfaces. The poly-urethane serves as sound deadening and insulation material, and the outer sides of opposed metallic sheets form the opposite surfaces of the partition. The opposed sheets are insulated from each other with respect to direct conduction of heat from one metallic surface to the other by means of neoprene or vinyl spacers which are clamped over the edges of the side portions of one metallic sheet and form abutment stops with respect to the interior surface of the adjacent coacting metallic sheet. These neoprene or vinyl spacers serve in two ways: l) to eliminate any transmission of cold via metal to metal contact and (2) to allow the poly-urethane foam to completely insulate the space between the interior surface of one metallic sheet and the interior surface of the coacting metallic sheet. I also provide a coupling member formed from neoprene or vinyl material disposed between overlapping surfaces of the metallic sheets at one side of the partition for establishing a heat and moisture seal between the aligned metallic sheets forming one side of the wall structure.

Referring to the drawings in more detail, reference character 1 designates one side of the sandwich wall unit of my invention while reference character 2 designates the coacting metallic sheet forming the other side of the sandwich wall unit. I have found that these metallic sheets may be pressed or rolled from aluminum sheet material, the metallic sheet which is formed in the shape of a trough or pan hav-ing side portions 3 and 4 extending substantially normal thereto. In each of these side portions I provide a longitudinally extending outstruck rib of V- shaped contour represented at 5 and 6, each extending in the same direction with respect to the side portions 3 and 4 coacting with similarly formed ribs such as rib 7 in the adjacent metallic section 8 and rib 9 in adjacent metallic section 10. The side portions 3 and 4 of the section 1 establish surface to surface ycontact relationship with the side portions 11 and 12 of adjacent sections 8 and 10 of the partition structure. Side portions 4 and 12 extend beyond the inter-lock provided by the V-shaped ribs 6 and 9 where side portion 4 is folded over upon itself as represented at 14, providing a groove into which the edge of side portion 12 extends as a tongue. This folded connection serves as a rib support for a multiplicity of neoprene or vinyl pins represented at 15. These pins include a spacer head 16 and 4a pair of gripping arms 17 and 18 shown more clearly in FIGS. l2-l4. The gripping arms 17 and 13 have sulicient resilience to enable the device to be clipped onto the folded-over edge 14 which interconnects sections 1 and lll with the head 16 projecting beyond the folded-over edge 14. The adjacent sections which do not include the folded-over edge couplet, such as sections 1 and 8 have their coacting end to end longitudinally extending sides 3 and 11 substantially face to face and providing a support for neoprene or vinyl continuous length end spacer members shown at 19 and illustrated in more detail in FIGS. -17. These spacers include a hookshaped extension at lone side thereof adapted to engage over the edge of one of the sides lof the `section such as side 3 as shown in FIG. 2 and extend along the entire sides of the section as indicated in FIGS. 6 and 7 to close both sides of the section and to act as stops for the poly-urethane foam. In FIG. 6 I have shown the manner of mounting the spacers 19 adjacent each other.

The space provided in each of the sections 1, u and 10, for example, is filled with the poly-urethane foam which I have indicated generally at 21 and which `conforms with the inner contour of the partition plate represented at 2. The partition plate 2 is formed in a hat section as represented more clearly in FIG. 8 that is rolled to provide a plurality of interconnecting .face sheets 22 and hat sections disposed therebetween as indicated at 23. The hat sections 23 are so proportioned that the end plates 3 and 11 and 4 and 12 of the adjacent sections 1, 3 and 10 are disposed intermediate the width of the hat sections in such manner that the spacer members 15 and 19 of insulation material form obstructions against the conduction or transmission of heat or cold from one metallic partition plate such as 1 to the coacting metallic partition plate such as 2. The insulation material 15 and 19 is disposed in series with the terminating ends of the side plates 3, 11, and 4, 12, and the interior sides of the hat sections 23 of the coacting partition plate 2. The gap represented at 24 maintained between the internal face of metallic partition plate 2 and the upper peripheral edges of the side plates 4 and 12 is also lilled with poly-urethane foam, Direct heat or cold conduction between partition plates 1 and 2 is obstructed by the spacer members 15 and 19.

The ends of the metallic plate 2 overlap with correspondingly shaped ends of adjacent metallic partition plates as represented at 25. The slight gap which remains between the overlapping portions of plates 2 and 25 is closed by a neoprene or vinyl insert represented at 26 in FIGS. 9-11. This insert includes a multiplicity of transversely extending spaced ribs 27, 28, 29, 30, 31 and 32 which project beyond the rear surface of the insert and establish a contact with the overlapping portion of a coacting partition plate represented in FIGS. l and 2, for example, at 25. The neoprene or vinyl insert 26 includes a flat face which extends in intimate contact with the internal surface of that portion 23 of partition plate 2 while the ribs 27-32 establish sealing contact with spaced partitions along the surface of the hat portion 2S of the adjacent partition plate. There are a multiplicity of spaced ribs 27-32 and all of these when compressed into intimate surface contact with the hat portion of the adjacent partition plate insure a tight seal between the hat portions 23 and 25 of the adjacent partition plates. The neoprene or vinyl insert 26 runs the full length of the panel thus acting as a vertical sealer or side lap sealer when lapping panels together. As indicated earlier` there is one neoprene insert sealer 26 on each iinished formed panel.

The insulation characteristics of the poly-urethane .foam material 21 acting in combination with the neoprene or vinyl spacers 15 and 19 and the coupling members of neoprene or vinyl 26 imposed between the overlapping portions 23 and 25 of the hat sections of end-to-end aligned partition plates insure a sandwich wall of curtain wall structure having very substantial obstruction to the conduction or transmission of heat or cold. Partition plates 1, 8 and 1i) and the coacting partition plate 2 have a minimum surface area in contact so that heat conduction or cold transmission between the opposite partition plates is maintained at a minimum. The gaps 24 and the positive obstruction to heat or cold transmission by the interposition of spacer members 15 and 19 between the opposite partition plates coact to `reduce heat or cold conduction or transmission between the opposite partition plates to an absolute minimum.

Referring to FIG. 8, a typical panel consists of five pans such as indicated by reference character 1 secured together by means previously set forth. Neoprene spacers 15 are installed, on the four intermediate legs. These spacers are positioned approximately twelve inches on centers, staggered from leg to leg as shown in FIG. 8 and are only approximately one inch in length. Continuous length end spacer members 19 are used to seal the sides of the panel between the top partition plate containing the hat sections and the sides of the end pans. After assembling this pan with two continuous length spacers 19 and the staggered center spacers 15 the top partition plate or face sheet is placed on top, sitting iirmly on the neoprene spacers. The lfoaming action 4if then commenced and the poly-urethane or rigithane foam is allowed to fill the interior of the assembled panel, passing between the small spacers 15 and thus filling the void. The continuous length spacers 19 prevent the foam from running out the side of the panel. The ends of the panels are not sealed, but foam stop ends fastened to the conveyor on which the panels are filled are automatically removed after the panel has been completed and the foaming process has stopped.

While I have described my invention in certain of its preferred embodiments I realize that modifications may be made and desire that it be understood that no limitations upon my invention are intended other than may be imposed by the scope of the appended claims.

What I claim as new land desire to secure by Letters Patent of the United States, is as follows:

1. In a building construction, a multiplicity of panlike metallic members having flat plane surfaces extending in coplanar relation, side portions coextensive with said plane front surfaces, said side portions being aligned sideby-side, with the side of one pan-like member provided with a plane surface and an outstruck projection in said last mentioned plane surface substantially offset from the flat plane surface of said pan-like metallic members and fitting into a complementary instruck recess in the plane surface of the side of the adjacent pan-like member, a metallic sheet having a surface extending in generally parallel spaced relation to the plane surface of said panlike metallic member and in a plane normal to the planes of said side members, insulation members constructed of a thermal-insulation material carried by said side members and projecting into abutment with the internal surface of said metallic sheet and spacing the terminating edges of said side members away from the internal surface of said metallic sheet, and a composition of a thermal insulation material bonded to the internal surfaces of said pan-like metallic member and establishing Ya bond with the internal surface of said metallic sheet, the mechanical connections between said metallic members and said metallic sheet within the space enclosed thereby being comprised solely of the materials of said insulation members and of said composition.

2. A building construction as set forth in claim l in which said metallic sheet is provided with a multiplicity of spaced trough-like portions directed toward the interior of said pan-like metallic members with intermediate portions having plane areas coplanar with each other and extending in a plane normal to the planes of said side portions and wherein the insulation members carried by said side portions and projecting into abutment with the internal surface of the intermediate portions of said trough-like portions of said metallic sheet are lineal strips that establish a lineal contact with the internal surface of said trough-like portions of said metallic sheet 3. A partition structure for building comprising a plurality of intertted pan-like sections having the exterior plane surfaces thereof disposed in coplanar relation and defining one side of a partition, said pan-like sections having interfitted side portions projecting substantially normal to the plane of the faces of said pan-like sections, a filler of material resistant to thermo-conduction disposed in said pan-like sections and adhesively connected with the interior plane surface of each of said sections, a metallic cover sheet disposed in spaced relation to the interior plane faces of said sections and extending over said filler and over the terminating edges of said side portions and thermal-insulation members carried by the side portions of said pan-like sections and projecting toward the internal surface of said cover sheet comprising abutments spacing the internal surface of said cover sheet from the terminating edges of said side portions and constructed of a material resisting thermo-conduction between said pan-like sections and said cover sheet, and a bondage connection between said filler and the internal surface of said cover sheet, the mechanical connections between said pan-like sections and said cover sheet within the space enclosed thereby being comprised solely of the materials of said filler and of said thermal-insulation members.

4. A partition structure for building as set forth in claim 3 in which said thermal-insulation members are blocks of thermal-insulation material bifurcated on one end and having an abutment head on the other end, the bifurcation in said blocks engaging over the terminating edges of the side portions of said pan-like sections and the said abutment head establishing abutting contact with the internal surface of said cover sheet.

5. A partition structure for buildings as set forth in claim 3 in which said thermal-insulation members contain a recess at one side thereof for enveloping the adjacent terminating edges of the side portion of adjacent pan-like sections.

6. A partition structure for buildings as set forth in claim 3 in which said metallic cover sheet is provided with a plurality of inwardly directed recesses spaced by plane portions and wherein the internal surfaces of said plane portions establish contact with said thermal-insulation members and wherein the recesses in said cover sheet extend in spaced relation to the interior surfaces of said pan-like sections with said iiller of insulation material disposed intermediate the recesses and plane portions of said cover sheet and the interior surfaces of said panlike sections.

7. A partition structure for buildings as set forth in claim 3 in which said metallic cover sheet is divided into a multiplicity of separate sections with the adjacent ends thereof overlapping each other and a multiple ribbed strip of thermal-insulation material interposed between the overlapping ends of the separate sections of said cover sheet.

References Cited in the tile of this patent UNITED STATES PATENTS 484,413 Espitallier Oct. 18, 1892 1,988,115 Elphinstone Ian. 15, 1935 2,116,012() Gauvin May 3, 1938 2,180,317 Davis Nov. 14, 1939 2,585,082 Bollinger Feb. 12, 1952 2,605,788 Dieterich Aug. 12, 1952 2,696,281 Hedgren et al. Dee. 7, 1954 2,728,702 Simon et al Dec. 27, 1955 2,738,094 Fowler Mar. 13, 1956 2,874,652 Wilson Feb. 24, 1959 2,912,725 Ries Nov. 17, 1959 

